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IE101F

IMPORTANTINSTRUCTIONSLIQUID TRANSFER-VAPORRECOVERY COMPRESSORS

Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of Corken products must be made onlyby experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken products must comply with Corken instructions, applicable laws andsafety standards (such as NFPA Pamphlet 58 for LP-Gas and ANSI K61.1-1972 for Anhydrous Ammonia). (4) Transfer of toxic, dangerous, flammable or explosivesubstances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards.

Model No.

Serial No.

Date Purchased

Date Installed

Purchased From

Installed By

WARNINGInstall, use and maintain this equipment according to Corken, Inc. instructions and all applicablefederal, state, local laws and codes, and NFPA Pamphlet 58 for LP-Gas or ANSI K61.1-1989 forAnhydrous Ammonia. Periodic inspection and maintenance is essential.

CONTACTING THE FACTORYFor your convenience, the valve size and serial code are given on the valve nameplate. This serial codetells the month and year your valve was built. Space is provided below for you to keep a written record ofthis information.

Always include the valve size and serial code when ordering parts.

CORKEN ONE YEAR LIMITED WARRANTYCorken, Inc. warrants that its products will be free from defects in material and workmanship for a period of12 months following date of purchase from Corken. Corken products which fail within the warranty perioddue to defects in material or workmanship will be repaired or replaced at Corken’s option, when returned,freight prepaid to: Corken, Inc., 3805 N.W. 36th Street, Oklahoma City, Oklahoma 73112. Parts subject towear or abuse, such as mechanical seals, blades, piston rings, valves, and packing, and other partsshowing signs of abuse are not covered by this limited warranty. Also, equipment, parts and accessories notmanufactured by Corken but furnished with Corken products are not covered by this limited warranty andpurchaser must look to the original manufacturer’s warranty, if any. This limited warranty is void if the Corkenproduct has been altered or repaired without the consent of Corken. All implied warranties, including anyimplied warranty of merchantability or expressed warranty period. CORKEN DISCLAIMS ANY LIABILITYFOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR IMPLIED WARRANTY ONCORKEN PRODUCTS. Transfer of toxic, dangerous, flammable or explosive substances using Corkenproducts is at the user’s risk. Such substances should be handled by experienced, trained personnel incompliance with governmental and industrial safety standards.

IMPORTANT NOTE TO CUSTOMERS!

CORKEN, INC. does not recommend ordering parts from general descriptions in this manual. To minimize thepossibility of receiving incorrect parts for your machine, Corken strongly recommends you order partsaccording to part numbers in the Corken Service Manual. If you do not have the appropriate service manualpages, call or write Corken with model number and serial number from the nameplate on your compressor.

TABLE OF CONTENTS

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4Liquid Transfer by Vapor Differential Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Residual Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Compressor Construction Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. INSTALLING YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 9Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Liquid Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Driver Installation / Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Truck Mounted Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Shutdown/Alarm Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3. STARTING UP YOUR CORKEN COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 17Inspection After Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Crankcase Oil Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. ROUTINE MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5. ROUTINE SERVICE AND REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Cylinder and Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Piston Rings and Piston Ring Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Wrist Pin Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Servicing the Four-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6. EXTENDED STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 29

APPENDIXA. Model Number and Mounting Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30B. Material Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31C. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32D. Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33E. Clearance and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34F. LPG Liquid Transfer Compressor Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35N-Butane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

G. Compressor Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38H. Compressor Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Liquid Transfer-Vapor Recovery Compressors

1.1 LIQUID TRANSFER BY VAPOR DIFFERENTIAL PRESSURE

Corken LPG/NH3 compressors are designed totransfer liquefied gases such as butane/propane

mixtures (liquefied petroleum gas or LPG) andAnhydrous Ammonia (NH3) from one tank toanother. Liquefied gases such as LPG & NH3 arestored in closed containers where both the liquidand vapor phases are present.

CHAPTER ONE

INTRODUCTION

CONSTRUCTION DETAILS - MODEL 491FIGURE 1.1A

Liquid Transfer-Vapor Recovery Compressors 5

There is a piping connection between the vaporsectons of the storage tank and the tank beingunloaded, and there is a similar connection betweenthe liquid secitons of the two tanks. If theconnections are opened, the liquid will seek its ownlevel and then flow will stop; however, by creating apressure in the tank being unloaded which is highenough to overcome pipe friction and any staticelevation difference between the tanks, all the liquidwill be forced into the storage tank quickly (seeFigure 1.1C). The Gas Compressor accomplishesthis by withdrawing vapors from the storage tank,compressing them and then discharging into thetank to be unloaded. This procedure slightlydecreases the storage tank pressure and increasesthe pressure in the other tank, thereby causing theliquid to flow.

The process of compressing the gas also increasesthe temperature, which aids in increasing thepressure in the tank being unloaded.

LIQUID TRANSFER BY VAPOR DIFFERENTIAL PRESSUREFIGURE 1.1C

TYPICAL NAMEPLATE(Also Serves as the Packing Adjusting Screw Cover)

FIGURE 1.1B


1.2 RESIDUAL VAPOR RECOVERY

The Principle of Residual Vapor Recovery is just theopposite of Liquid Transfer. After the liquid has beentransferred, the Four-Way Control Valve (or alternatevalve manifolding) is reversed so that the vapors aredrawn from the tank just unloaded and dischargedinto the receiving tank. Always discharge therecovered vapors into the liquid section of thereceiving tank. This will allow the hot, compressedvapors to condense, preventing an undesirableincrease in tank pressure. See Figure 1.2A.

Residual Vapor Recovery is an essential part of thevalue of a Compressor. There is an economical limitto the amount of vapors that should be recovered,however. When the cost of operation equals theprice of the product being recovered, the operationshould be stopped. For most cases in LP Gas andAnhydrous Ammonia services, this point is reachedin the summer when the compressor inlet pressureis 40 to 50 psig (3.8 to 4.5 Bars). A good rule of

thumb is not to operate beyond the point at whichthe inlet pressure is one-fourth the dischargepressure. Some liquids are so expensive that furtherrecovery may be profitable, but care should be takenthat the ratio of absolute discharge pressure toabsolute inlet pressure never exceeds 7 to 1. Furtherexcavation of very high value products would requirea Corken Two-Stage Gas Compressor.

Invariably, there is some liquid remaining in the tankafter the liquid transfer operation. This liquid “heel”must be vaporized before it can be recovered, so donot expect the pressure to drop immediately.Actually, more vapor will be recovered during thefirst few minutes while this liquid is being vaporizedthan that during the same period of time later in theoperation. Remember that more than half of theeconomically recoverable product is usuallyrecovered during the first hour of operation onproperly sized equipment.

RESIDUAL VAPOR RECOVERYFIGURE 1.2A


1.3 COMPRESSOR CONSTRUCTION FEATURES

The Corken liquid transfer-vapor recoverycompressor is a vertical single-stage, single-actingreciprocating compressor designed to handleflammable gases like LPG and toxic gases such asammonia. Corken compressors can handle thesepotentially dangerous gases because the LPG/NH3is confined in the compression chamber and isolatedfrom the crankcase and the atmosphere. A typicalliquid transfer-vapor recovery compressor packageis shown in Figure 1.3A.

Corken gas compressors are mounted on oillubricated crankcases that remain at atmosphericpressure. Crankshafts are supported by heavy-dutyroller bearings and the connecting rods ride thecrankshaft on journal bearings. With the exception of

the small Size 91 compressor, all compressorcrankcases are lubricated by an automotive type oilpressure system. An automatically reversible geartype oil pump circulates oil through passages in thecrankshaft and connection rod to lubricate thejournal bearings and wrist pins (see Figure 1.3B).Sturdy iron crossheads transmit reciprocatingmotion to the piston.

Corken’s automatically reversible oil pump designallows the machine to function smoothly in eitherdirection of rotation.

Corken compressors use iron pistons that are lockedto the piston rod. The standard piston ring material isa glass-filled PTFE polymer specially formulated fornonlubricated services. Piston ring expanders areplaced behind the rings to ensure that the pistonrings seal tightly against the cylinder wall.

107-STYLE COMPRESSOR MOUNTINGFIGURE 1.3A

PRESSURE LUBRICATION SYSTEMFIGURE 1.3B


Piston rod packing is used to seal the gas in thecompression chamber and prevent crankcase oilfrom entering the compressor cylinder. The packingconsists of several PTFE V-rings sandwichedbetween a male and female packing ring and held inplace by a spring (see Figure 1.3C).

The typical Corken compressor valve consists of aseat, bumper, spring and valve disk as shown inFigure 1.3D. Special heat-treated alloys are utilizedto prolong life of the valve in punishing non-lubricated services. The valve opens whenever thepressure on the seat side exceeds the pressure onthe spring side. The discharge valve is an invertedversion of the suction valve.

COMPRESSOR SEALING SYSTEMFIGURE 1.3C

SUCTION AND DISCHARGE VALVESFIGURE 1.3D


2.1 LOCATION

Corken compressors are designed and manufacturedfor outdoor duty. For applications where thecompressor will be subjected to extreme conditionsfor extended periods such as corrosive environments,arctic conditions, etc., consult Corken. Check localsafety regulations and building codes to assureinstallation will meet local safety standards.

Corken compressors handling toxic or flammablegases such as LPG/NH3 should be located outdoors.A minimum of 18 inches (45 cm) clearance betweenthe compressor and the nearest wall is advised tomake it accessible from all sides and to provideunrestricted air flow for adequate cooling.

NOISE. Corken vertical compressors sizes 91through 691 will not exceed an 85 DBA noise levelwhen properly installed.

2.2 FOUNDATION

Proper foundations are essential for a smoothrunning compression system. Corken recommendsthe compressor be attached to a concrete slab atleast 8” thick with a 2” skirt around the circumferenceof the baseplate. The baseplate should be securelyanchored into the foundation by 1/2” diameter “J”bolts 12” long. The total mass of the foundationshould be approximately twice the weight of thecompressor system (compressor, baseplate, motor,etc.). After leveling and bolting down baseplate, thevolume beneath the channel iron baseplate must begrouted to prevent flexing of the top portion of thebaseplate and the “J” bolt that extends beyond thefoundation. The grout also improves the dampeningcapabilities of the foundation by creating a solidinterface between the compressor and foundation.

On some of the longer baseplates, such as the 691107, a 3-inch hole can be cut in the baseplate forfilling the middle section of the channel iron basewith grout.

2.3 PIPING

Proper piping design and installation is as importantas the foundation is to smooth operation of thecompressor. Improper piping installation will result inundesirable transmission of compressor vibration tothe piping.

DO NOT SUPPORT PIPING WITH THECOMPRESSOR. Unsupported piping is the mostfrequent cause of vibration of the pipe. The bestmethod to minimize transmission of vibration fromthe compressor to the piping is to use flexibleconnectors (see Figure 2.3A).

RECOMMENDED FOUNDATION DETAILS FORCORKEN COMPRESSORS 91 - 691

FIGURE 2.2A

2” MIN.ALL SIDES

8” MIN.

HEX NUT

WASHERCOMPRESSORBASEPLATE

GROUT BENEATHBASE

CONCRETE FOUNDATIONWITH REINFORCEMENTSSHOULD BE USED ONALL MODELS

1/2” “J” BOLTS12” LONG

NOTE:LOCATE “J” BOLTS PERCOMPRESSOR OUTLINEDIMENSION DRAWINGS.

CHAPTER TWO

INSTALLING YOUR CORKEN COMPRESSOR

Pipe must be adequately sized to prevent excessivepressure drop between the suction source and thecompressor as well as between the compressor andthe final discharge point. In most cases, pipingshould be at least the same diameter as the suctionnozzle on the compressor. Typically, LPG/NH3 liquidtransfer systems should be designed to limitpressure drops to 20 PSI (1.3 Bar). Appendix Fshows recommended pipe sizes for eachcompressor for typical LPG/NH3 installations.

Care must be taken if a restrictive device such as avalve, pressure regulator, or back-check valve is tobe installed in the compressor’s suction line. Thesuction line volume between the restrictive deviceand the compressor suction nozzle must be at leastten times the swept cylinder volume.

107 style compressors are usually connected usinga five-valve (Figure 2.3B) or three-valve manifold(Figure 2.3C). The five-valve manifold allows thestorage tank to be both loaded and unloaded. Thethree-valve manifold only allows the storage tank tobe loaded. Adequate sizing of the liquid and vaporlines is essential to limit the pressure drop in thesystem to a reasonable level (20 psi or less).

The line size helps determine the plant capacityalmost as much as the size of the compressor, andliquid line sizes are a bigger factor than vapor lines.If the pressure gauges on the head indicate morethan a 15 to 20 psi (2.07 to 2.40 Bars) differentialbetween the inlet and outlet pressures, the line sizesare too small or there is some fitting or excess flow

valve creating too much restriction. The lessrestriction in the piping, the better the flow. AppendixF shows recommended pipe sizes for typicalLPG/NH3 compressor installation.

A tank car unloading riser should have two liquidhoses connected to the car liquid valves. If only oneliquid hose is used the transfer rate will be slower,and there is a good possibility that the car’s excessflow valve may close.

Since the heat of compression plays an importantpart in rapid liquid transfer, the vapor line from thecompressor to the tank car or other unloadingcontainer should be buried or insulated to preventthe loss of heat and the compressor should belocated as near as possible to the tank beingemptied. In extremely cold climates, if the line fromthe storage tank to the compressor is over 15 feet(4.6 meters) long, it should be insulated to lessen thepossibility of vapors condensing as they flow to thecompressor. The vapor recovery discharge line isbetter not insulated. Placing the compressor asclose as possible to the tank being unloaded willminimize heat loss from the discharge line for thebest liquid transfer rate.

Unloading stationary tanks with a compressor isquite practical. Delivery trucks and other largecontainers can be filled rapidly if the vapor system ofthe tank to be filled will permit fast vapor withdrawal,and if the liquid piping system is large enough. Manyolder trucks (and some new ones) are not originallyequipped with vapor excess flow valves largeenough to do a good job and these should bereplaced by a suitable size valve. The liquiddischarge should be connected to the tank truckpump inlet line rather than the often oversized fillervalve connection in the tank head.

It is of extreme importance to prevent the entry ofliquid into the compressor. The inlet of thecompressor should be protected from liquid entry bya liquid trap (see Section 2.4). It is of equalimportance to protect the discharge of thecompressor from liquid. This may be done byinstalling a check valve on the discharge anddesigning the piping so liquid cannot gravity-drainback into the compressor. Make sure to install acheck valve on vapor lines discharging to the liquidspace of the tank.


FIGURE 2.3A


All piping must be in accordance with the laws andcodes governing the service. In the United States,the following codes apply:

For LP Gas – The National Fire Protection AssociationPamphlet No. 58, Standard for the Storage andHandling of Liquefied Petroleum Gases.

For Ammonia – The American National StandardsInstitute, Inc., K61.1-1989, Storage and Handling ofAnhydrous Ammonia.

Copies of these are available from NFPA, 60Baterymarch Street, Boston, Mass, 02110 and ANSI,1430 Broadway, New York, N.Y., 10018. Install, useand maintain this equipment according to Corkeninstructions and all applicable federal, state, andlocal laws and previously mentioned codes.

FIVE-VALVE MANIFOLD PIPING SYSTEMFIGURE 2.3B

SERVICE TO PERFORM VALVE POSITION

4-WAY A B C D E

1. Unload Tank Car into Position Open Open Close Close CloseStorage Tank One

2. Recover Vapors from Tank Position Close Open Open Close CloseCar into Storage Tank Two

3. Unload Transport or Truck Position Open Close Close Close Openinto Storage Tank One

4. Recover Vapors from Transport Position Close Close Open Close Openor Truck into Storage Tank Two

5. Load Truck or Field Tank Position Open Close Close Close Openfrom Storage Tank Two

6. Load Truck or Field Tank Position Close Open Close Open Closefrom Tank Car One

7. Equalize Between Tank Car --- Open Open Close Open Openand Storage Tank Withoutusing Vapor Pump

8. Equalize Between Truck or --- Open Close Close Open CloseField Tank and Storage TankWithout Using Vapor Pump


2.4 LIQUID TRAPS

Compressors are designed to pressurize gas, not topump liquids. The entry of even a small amount ofliquid into the compressor will result in seriousdamage to the compressor.

On liquefied gas applications a liquid trap must beused to prevent the entry of liquid into the compressor.

Corken offers three types of liquid traps for removalof entrained liquids. The simplest is a float trap (seeFigure 2.4A). As the liquid enters the trap the gasvelocity is greatly reduced, which allows theentrained liquid to drop out. If the liquid level risesabove the inlet, the float will plug the compressorsuction. The compressor creates a vacuum in theinlet piping and continues to operate until theoperator manually shuts it down. The trap must bedrained and the vacuum-breaker valve openedbefore restarting the compressor, to allow the float todrop back. This type of trap is only appropriate foruse where the operator keeps the compressor underfairly close observation. This trap is provided withthe 109 and 107 compressor packages (see bottomof Appendix A for details on standard Corkencompressor packages).

THREE-VALVE MANIFOLD PIPING SYSTEMFIGURE 2.3C

MECHANICAL TRAPFIGURE 2.4A

SERVICE TO PERFORM VALVE POSITION

4-WAY A B C

1. Unload Tank Car into Position Open Open CloseStorage Tank One

2. Recover Vapors from Tank Position Close Open OpenCar into Storage Tank Two


When the compressor will not be under more-or-lessconstant observation an automatic trap isrecommended (see Figure 2.4B). The automatic trapreplaces the float with electrical float switches. If theliquid level should rise too high, the level switch willopen and disconnect the power to the motor starter,stopping the compressor. This design ensures themachine will be protected even when it is not underclose observation and is standard in the 109A and107A mounting configurations.

Corken’s most sophisticated trap provides the mostthorough liquid separation (see Figure 2.4C). Thistrap is larger and is ASME code stamped. It containstwo level switches, one for alarm and one forshutdown. In some cases the alarm switch is used toactivate a dump valve (not included with trap) orsound an alarm for the trap to be manually drainedby the operator. This trap also contains a mist pad. Amist pad is a mesh of interwoven wire to disentrainfine liquid mists. The ASME code trap is standard inthe -109B and -107B mounting configurations.

AUTOMATIC LIQUID TRAPFIGURE 2.4B

ASME AUTOMATIC TRAPFIGURE 2.4C


A typical wiring diagram for the liquid level switch isshown in Figure 2.4D. If the switch is installed withthe conduit connection in the top position, it will benormally closed as shown in Figure 2.4D. If theconduit is in the bottom position, the switch will benormally open.

NOTE: The level switch MUST be removed fromthe trap before grounding any welding devicesto the trap or associated piping! Failure to do sowill damage the switch contacts.

If your compressor is equipped with a liquid trapof other than Corken manufacture, make sure itis of adequate size to thoroughly remove anyliquid entrained in the suction stream.

2.5 DRIVER INSTALLATION / FLYWHEELS

Corken vertical compressors may be driven by eitherelectric motors or combustion engines (gasoline,diesel, natural gas, etc.). Corken compressors areusually V-belt driven but they are also suitable fordirect drive applications as well. Direct driveapplications require an extended crankshaft to allowthe attachment of a rigid metal coupling.

Note: flexible couplings are not suitable forreciprocating compressors. Never operate areciprocating compressor without a flywheel.

Drivers should be selected so the compressoroperates between 350 to 825 RPM. The unit mustnot be operated without the flywheel or severetorsional imbalances will result that could causevibration and high horsepower requirement. Theflywheel should never be replaced by another pulleyunless it has a higher wk2 value than the flywheel.

A humid climate can cause problems, particularly inexplosion proof motors. The normal breathing of themotor, and alternating between being warm whenrunning and being cool when stopped, can causemoist air to be drawn into the motor. This moist airwill condense, and may eventually add enoughwater inside the motor to cause it to fail. To preventthis, make a practice of running the motor at leastonce a week on a bright, dry day for an hour or sowithout the V-belts. In this period of time the motorwill heat up and vaporize the condensed moisture,driving it from the motor. No motor manufacturer willguarantee his explosion proof or totally enclosed(TEFC) motor against damage from moisture.

For installation with engine drivers, thoroughlyreview instructions from the engine manufacturer toassure the unit is properly installed.

2.6. CRANKCASE LUBRICATION

Non-detergent oil is recommended for Corken verticalcompressors. Detergent oils tend to keep wearparticles and debris suspended in the oil, whereasnon-detergent oils let them settle in the bottom of thecrankcase. When non-detergent oils are not available,detergent oils may usually be successfully substituted,although compressors handling ammonia, amine, orimine gases are notable exceptions. These gasesreact with the detergent and cause the crankcase oil tobecome corrosive and contaminated. Figures 2.6Aand 2.6B show recommended oil viscosities andcrankcase capacities.

Synthetic lubricants are generally not necessary.Please consult the Factory if you are considering theuse of synthetic oil.

FIGURE 2.4D

2.7 RELIEF VALVES

An appropriate relief valve must be installed at thecompressor discharge. On 107-style mounted unitsa relief valve should be fitted in the piping betweenthe compressor discharge and the four-way valve(see Figure 1.3A). Relief valves should be made of amaterial compatible with the gas being compressed.Local codes and regulations should be checked forspecific relief valve requirements. Also, relief valvesmay be required at other points in the compressor’ssystem piping.

2.8 TRUCK MOUNTED COMPRESSORS

Corken compressors are frequently mounted ontrucks to perform liquid transfer operations asdescribed in Section 1.1. The compressor should bemounted so the inspection plate is accessible forpacking adjustment. The compressor must beprotected against liquid as explained in Section 2.4and a relief valve must be installed in the dischargepiping before the first downstream shutoff valve.

Three types of mountings are typically used. Theinside mounting (Figure 2.8A) drives the compressordirectly off the PTO shaft. The PTO must be selectedto drive the compressor between 400 and 800 RPM.An extended compressor crankshaft is required sothe U-joint yoke may connect to the compressor

without removing the flywheel. Do not operate thecompressor without a flywheel. Use a U-joint with asplined joint and make sure the connections areparallel and in line. The U-joint angle should be lessthan 15 degrees (see Figure 2.8B). Always use aneven number of U-joints.


INSIDE TRANSPORT MOUNTINGFIGURE 2.8A

U-JOINT DRIVE FOR COMPRESSORFIGURE 2.8B

Ambient TemperatureAt Compressor SAE Viscosity

Below 0°F (-18°C) 5W, 5W-300° to 32°F (-18° to 0°C) 10W, 5W-30, 10W-4032°F to 80°F (0° to 27°C) 20, 5W-30, 10W-40Above 80°F (27°C) 30, 5W-30, 10W-40

Compressor Approximate CapacityModel Quarts Liters

91 0.9 0.8290, 291 1.5 1.4490, 491 3.0 2.8690, 691 7.0 6.6

OIL SELECTION CHARTFIGURE 2.6A

OIL CAPACITY CHARTFIGURE 2.8A


Depending on the truck design, the compressor maybe outside or top mounted as shown in Figures 2.8Cand 2.8D to be V-belt driven. Power is transmittedthrough a U-joint drive shaft, jackshaft with twopillow block bearings, V-belt sheave and V-belts. Anidle pulley may be used under the truck frame.

2.9 SHUTDOWN/ALARM DEVICES

For many applications, shutdown/alarm switches willprovide worthwhile protection that may preventserious damage to your compressor system. Allelectronic devices should be selected to meet localcode requirements. Shutdown/alarm devicestypically used on Corken compressors are:

Low Oil Pressure Switch - shuts down the unit ifcrankcase oil pressure falls below 12 psi due to oilpump failure or low oil level in crankcase.

High Temperature Switch - shuts down unit if thenormal discharge temperature is exceeded, and isstrongly recommended for all applications. Typically,the set point is about 30°F (-1°C) above the normaldischarge temperature.

Low Suction, High Discharge Pressure Switch -shuts down unit if inlet or outlet pressures are notwithin preset limits.

Vibration Switch - shuts down unit if vibrationbecomes excessive. Recommended for unitsmounted on portable skids.

OUTSIDE TRANSPORT MOUNTINGFIGURE 2.8C

TOP TRANSPORT MOUNTINGFIGURE 2.8D

NOTE: Before initial startup of the compressorbe sure the principal of using a compressor forliquid transfer by vapor differential pressure isunderstood (see Section 1.1). Read this entirechapter, then proceed with the startup checklist.

3.1 INSPECTION AFTER EXTENDED STORAGE

If your compressor has been out of service for a longperiod of time, you should verify that the cylinderbore and valve areas are free of rust and otherdebris (see the maintenance section of this manualfor valve and/or cylinder head removal instructions).

Drain the oil from the crankcase and remove thenameplate and crankcase inspection plate. Inspectthe running gear for signs of rust and clean orreplace parts as necessary. Replace the crankcaseinspection plate and fill crankcase with theappropriate lubricant. Squirt oil on the X-heads androtate the crank by hand to ensure that all bearingsurfaces are coated with oil.

Rotate unit manually to ensure running gearfunctions properly. Replace nameplate and proceedwith startup.

3.2 FLYWHEEL AND V-BELT ALIGNMENT

Before working on the drive assembly, be sure that theelectric power is disconnected. When mounting newbelts, always make sure the driver and compressor areclose enough together to avoid forcing.

Improper belt tension and sheave alignment cancause vibration, excessive belt wear and prematurebearing failures. Before operating your compressor,check alignment of the V-grooves of the compressorand driver sheaves: visual inspection often willindicate if the belts are properly aligned, but use of asquare is the best method.

The flywheel is mounted on the shaft via a split,tapered bushing and three bolts. These bolts shouldbe tightened in an even and progressive manneruntil torqued as specified below. There must be agap between the bushing flange and the sheave

when installation is complete. Always check theflywheel runout before startup and readjust if itexceeds the value listed in Appendix E.

Tighten the belts so that they are taut, but notextremely tight. Consult your V-belt supplier forspecific tension recommendations. Belts that are tootight may cause premature bearing failure.


FLYWHEEL INSTALLATIONFIGURE 3.2A

CHAPTER 3

STARTUP UP YOUR CORKEN COMPRESSOR

Bushing Diameter Bolt TorqueSize In. (cm) Ft.-lb. (kg-meter)

SF 4.625 (11.7) 30 (4.1)E 6.0 (15.2) 60 (8.3)J 7.25 (18.4) 135 (18.7)


3.3 CRANKCASE OIL PRESSUREADJUSTMENT

Corken compressor models 291 through 691 areequipped with an automatically reversible gear typeoil pump (if your compressor is the splash lubricatedModel 91, proceed to Section 3.4). It is essential toensure the pumping system is primed and the oilpressure is properly adjusted in order to assuresmooth operation.

Before starting your compressor, check and fillcrankcase with the proper quantity of lubricating oil(see Figure 5.5A for proper filling location).

When the compressor is first started, observe thecrankcase oil pressure gauge. If the gauge fails toindicate pressure within 30 seconds, stop themachine. Remove the pressure gauge. Restart thecompressor and run it until oil comes out of thepressure gauge opening. Reinstall the gauge.

The oil pressure should be about 20 psi (2.4 Bars)minimum for normal service. If the dischargepressure is above 200 psi (14.8 Bars) the oilpressure must be maintained at a minimum of 25psi (2.7 Bars). A spring-loaded relief valvemounted on the bearing housing opposite theflywheel regulates the oil pressure. As shown inFigure 3.3A, turn the adjusting screw clockwise toincrease the oil pressure and counterclockwise tolower it. Be sure to loosen the adjusting screwlocknut before trying to turn the screw and tightenit after making any adjustment.

FLYWHEEL INSTALLATIONFIGURE 3.3A


Before Starting the Compressor

1. Become familiar with the function of all pipingassociated with the compressor. Know eachline’s use!

2. Verify that actual operating conditions will matchthe anticipated conditions.

3. Ensure that line pressures are within cylinderpressure ratings.

4. Clean out all piping.

5. Check all mounting shims, cylinder and pipingsupports to ensure that no undue twisting forcesexist on the compressor.

6. Verify that strainer elements are in place and clean.

7. Verify that cylinder bore and valve areas are clean.

8. Check V-belt tension and alignment. Check drivealignment on direct drive units.

9. Rotate unit by hand. Check flywheel for wobbleor play.

10. Check crankcase oil level.

11. Drain all liquid traps, separators, etc.

12. Verify proper electrical supply to motor and panel.

13. Check that all gauges are at zero level reading.

14. Test piping system for leaks.

15. Purge unit of air before pressurizing with gas.

16. Carefully check for any loose connections or bolts.

17. Remove all stray objects (rags, tools, etc.) fromvicinity of unit.

18. Verify that all valves are open or closed as required.

19. Double-check all of the above.

After Starting Compressor

1. Verify and note proper oil pressure. Shut downand correct any problem immediately.

2. Observe noise and vibration levels. Correctimmediately if excessive.

3. Verify proper compressor speed.

4. Examine entire system for gas, oil or water levels.

5. Note rotation direction.

6. Check start-up voltage drop, running amperageand voltage at motor junction box (not at thestarter).

7. Test each shutdown device and record set points.

8. Test all relief valves.

9. Check and record all temperatures, pressuresand volumes after 30 minutes and 1 hour.

10. After 1 hour running time, tighten all head bolts,valve holddown bolts, and baseplate bolts.

3.4 STARTUP CHECK LISTPlease verify all of the items on this list before starting your compressor! Failure to do somay result in a costly (or dangerous) mistake.


ITEM TO CHECK Daily Weekly Monthly Six Months Yearly

Crankcase Oil Pressure X

Compressor Discharge Pressure X

Overall Visual Check X

Crankcase Oil Level ** **

Drain Liquid from Accumulation Points X*** X***

Drain Distance Piece X

Clean Cooling Surfaces on XCompressor and Intercooler

Lubricator Supply Tank Level X

Check Belts for Correct Tension X

Inspect and Clean Filter Felts on XControl Pilot (Valve Spec. 78, 8)

Inspect and Clean Filter Felts on Crankcase XHydraulic Unloader (Valve Spec. 7, 78)

Inspect Valve Assemblies X

Lubricate Motor Bearings in Accordance with XManufacturers’ Recommendations

Inspect Motor Starter Contact Points X

Piston Rings * X

* Piston ring life varies greatly, depending on application, gas, and operating pressures. Consult factoryfor additional recommendations for your specific applications.

** Change oil every 2200 hours of operation or every 6 months, whichever occurs first. If the oil is unusuallydirty, change it as often as needed to maintain a clean oil condition. Change replacement filter 4225 withevery oil change.

*** Liquid traps should be drained prior to startup.

CHAPTER 4

ROUTINE MAINTENANCE CHART


CAUTION: Always relieve pressure in the unitbefore attempting any repairs. After repair, theunit should be pressure tested and checked forleaks at all joints and gasket surfaces.

If routine maintenance is performed as outlined inChapter 4, repair service on your Corken GasCompressor is generally limited to replacing valvesor piston rings. When it comes time to orderreplacement parts, be sure to consult your CorkenService Manual, Section E, for the correct partnumber and include the Compressor Model andSerial Number.

5.1 VALVES

Test the Compressor valves by closing the inletpiping valves while the unit is running; do not allowthe machine to operate in this way very long,however. If the inlet pressure gauge does not drop tozero almost immediately, one or more of the valvesis probably either damaged or dirty. It is possible ofcourse, that the pressure gauge itself is faulty.

To remove and inspect valves, begin bydepressurizing and purging (if necessary) the unit.Next, remove the valve cap and then remove thevalve holddown screw (see Figure 5.1A through5.1C) with the special wrench supplied with thecompressor. Valves in sizes 91 through 291 maythen be removed. Sizes 491 through 691 requireremoval of the valve cover plate before the valvescan be removed.

Inspect valves for breakage, corrosion, andscratches on the valve disc and debris. In manycases, valves may simply be cleaned andreinstalled. If the valves show any damage, theyshould be repaired or replaced. Replacement isusually preferable, although repair parts areavailable. If valve discs are replaced, seats shouldalso be lapped until they are perfectly smooth. Ifmore than .005” must be removed to achieve asmooth surface, the valve should be discarded. Ifdiscs are replaced without relapsing the seat, rapidwear and leakage may occur.

CHAPTER 5

ROUTINE SERVICE AND REPAIR PROCEDURES

COMPRESSOR SIZES 91, 290, 291FIGURE 5.1A


The metal valve gasket should always be replacedwhen the valve is reinstalled. Make sure suction anddischarge valves are in the right slots as shown inthe illustrations. Reinstall cages and spacers, thentighten the valve hoiddown screw to the value listedin Appendix D to ensure the valve gasket is properlyseated. O-rings sealing the valve cover and valvecap should be replaced if they show any signs ofwear or damage. Valve caps sealed by flat metalgaskets should be reinstalled with new gaskets.Refer to Appendix D for torque values.

*Some Spec 3 suction valves have an adjustingscrew to set the liquid relief pressure. To adjust,tighten the adjusting screw until it bottoms, then backone turn on the size 491. (91/291/691’s are pre-set).

COMPRESSOR SIZE 491FIGURE 5.1B

COMPRESSOR SIZE 691FIGURE 5.1C


5.2 CYLINDERS AND HEAD

Cylinders and heads very seldom requirereplacement if the compressor is properlymaintained. The primary cause of damage tocylinders and heads are corrosion and the entry ofsolid debris or liquid into the compression chamber.Improper storage can also result in corrosiondamage to the head and cylinder (for proper storageinstructions see Section 5.8).

If the cylinder does become damaged or corroded,use a hone to smooth the cylinder bore and thenpolish it to the value shown in Appendix E. If morethan .005” must be removed to smooth the bore,replace the cylinder. Cylinder liners and oversizedrings are not available. Overboring the cylinder willresult in greatly reduced ring life.

Many compressor repair operations require removalof the head and cylinder. While the compressor isdisassembled, special care should be taken to avoiddamage or corrosion to the head and cylinder. If thecompressor is to be left open for more than a fewhours, bare metal surfaces should be coated withrust preventative.

When reassembling the compressor, make sure thebolts are retightened as shown in Appendix D.

5.3 PISTON RINGS AND PISTON RINGEXPANDERS

Piston ring life will vary considerably from applicationto application. Ring life will improve dramatically atlower speeds and temperatures.

To replace the piston rings: Depressurize thecompressor and purge if necessary. Remove thehead to gain access to the compressor cylinder.Loosen the piston head bolts. Remove the piston asshown in Figure 5.3A by pinching two loose boltstogether. Piston rings and expanders may then beeasily removed and replaced. Corken recommendsreplacing expanders whenever rings are replaced.

To determine if rings should be replaced, measurethe radial thickness and compare it to the chart inAppendix E.

5.4 PISTONS

To replace the pistons: Depressurize the compressorand purge if necessary. Remove the compressorcylinder and head (see Section 5.2). Remove the pistonhead by loosening and removing the socket head boltsholding the piston head to the piston platform (seeFigure 5.3A). Next, remove the roll pin with a pair ofneedle nose pliers. The castellated nut may now beremoved and the piston platform lifted off the end of thepiston rod. Check the thrust washer and shims fordamage and replace if necessary.

Before installing the new piston, measure thethickness of the existing shims. For Models 91through 491, the shims are placed between thethrust washer and piston platform. For model 691,the shims are placed between the platform andpiston head (see Figure 5.4A and 5.4B).

Reinstall the piston platform with the same thicknessof shims as before, BUT DO NOT REINSTALL THEROLL PIN. Replace the cylinder and install the pistonheads with new piston rings and expanders. Nowmeasure dimension “X” shown in the illustration. Ifthis measurement does not fall within the tolerancesshown in Appendix E, remove the piston, adjust theshims as necessary and remeasure the “X”dimension. When the piston is properly shimmed,tighten the castellated nut as shown in Appendix D.Now install a new roll pin to lock the castellatedpiston nut in place. Install the piston head and tightenthe socket head bolts in an alternating sequence.Reinstall the head (see Section 5.5) and followstandard startup procedure. (Note: New compressorsmay have self-locking nuts without roll pins.)

PISTON REMOVALFIGURE 5.3A


5.5 PISTON ROD PACKINGADJUSTMENT

Piston rod packing should be adjusted or replacedwhenever leakage becomes noticeable. Typically, itis a good idea to replace piston rod packing andpiston rings at the same time.

Instructions for packing replacement are includedwith each set of packing.

Inspection of the rod packing is generally notproductive, since packing that cannot be adjusted toan acceptable leakage rate should be replaced.

To adjust the packing, remove the compressornameplate, tighten the packing adjusting nut(s) 1/4turn with the wrench supplied, then run thecompressor a few minutes to reseat the packing. Ifthe leakage is still unacceptable, tighten theadjusting nut as necessary, using 1/4 turns at a time.Do not overtighten! If the adjusting nut is tighteneduntil the packing spring is solid, the packing shouldbe replaced. If packing will not seal, carefully inspectpiston rods for possible scoring. Replace if needed.

Reattach the compressor nameplate after adjustmentsor repairs are made.

PISTON CROSS SECTIONSIZES 91 THROUGH 491

FIGURE 5.4A

PISTON CROSS SECTIONSIZE 691

FIGURE 5.4B

PACKING ADJUSTING NUTSFIGURE 5.5A


5.6 BEARING REPLACEMENT

To replace the crankcase roller bearings, wrist pinbushing and connecting rod bearings, begin byremoving the head, cylinder, piston, crosshead guideand crosshead. Drain the crankcase and remove theinspection plates. Loosen and remove theconnecting rod bolts in order to remove thecrosshead/connecting rod assembly.

5.6.1 WRIST PIN BUSHINGREPLACEMENT

To replace the wrist pin bushing, remove the retainerrings that position the wrist pin in the crosshead.Press out the wrist pin so the crosshead andconnecting rod may be separated. Inspect the wristpin for wear and damage and replace if necessary.

Press out the old wrist pin bushing and press a newbushing into the connecting rod. DO NOT MACHINETHE O.D. OR I.D. OF THE BUSHING BEFOREPRESSING INTO CONNECTING ROD. Make surethe lubrication hole in the bushing matches the oilpassage in the connecting rod. If the holes do notalign, drill out the bushing through the connectingrod lubricant passage with a long drill. Bore the wristpin bushing I.D. as indicated in Appendix E.Overboring the bushing can lead to prematurefailure of the wrist pin bushing. Inspect the oilpassage for debris. Clean thoroughly beforeproceeding. Press the wrist pin back into thecrosshead and wrist pin and reinstall retainer rings.NOTE: The fit between the wrist pin and bushing istighter than on ordinary lubricated air compressorsand combustion engines.

5.6.2 CONNECTING ROD BEARINGS

Connecting rod bearings are easily replaced afterremoving the semicircular inserts. Make sure theindentations in the connecting rod bearing andconnecting rod line up when installing the new bearings.

Before reinstalling the crosshead/connecting rodassembly, make sure the crankshaft throw and bearingsurface are clean and lubricated. Tighten theconnecting rod bolts to the torques listed in Appendix D.

5.6.3 ROLLER BEARINGS

To inspect the roller bearings, remove the flywheelfrom the crankshaft and then remove the bearingcarrier and crankshaft from the crankcase. If corrosionor pitting is present, the roller bearing should bereplaced. When replacing roller bearings, alwaysreplace the entire bearing, not just the cup or the cone.

To replace the bearings, press the cups out of thecrankcase and bearing carrier and press the conesoff the crankshaft. Press the new bearings intoposition and reassemble the crankshaft and bearingcarrier to the crankcase. When reinstalling thebearing carrier, make sure the oil pump shaft slot isaligned with the pin in the crankshaft. Make sure toinstall the bearing carrier gasket so the oil passagehole is not blocked (see Figure 5.6.3A).

In order to check the crankshaft end play, the oilpump must first be removed (see Section 5.7). Pressthe end of shaft towards the crankcase; if a clickingnoise or motion is detected, the crankshaft has toomuch end play. To reduce end play, remove thebearing cover and remove a thin shim. Recheck theend play after replacing the bearing cover. Whenthere is no detectable end play, the shaft must still beable to rotate freely. If the shaft sticks or becomesabnormally warm, then the crankshaft bearings aretoo tight. If the shaft is too tight, add more shims butmake sure not to overshim. (Appendix E lists theproper crankshaft end play).

When the shaft can be rotated freely by hand and noend play is present, the rest of the compressor may bereassembled. If the crankshaft roller bearings are tootight or too loose, premature bearing failure will result.

Reinstall the flywheel on the crankshaft and checkthe run out as shown in Appendix E.


5.7 OIL PUMP INSPECTION

If the compressor operates for a prolonged periodwith dirty or contaminated crankcase oil, damage tothe oil pump may result. To check the oil pump,unbolt the pump cover and remove the oil pump,spring guide, spring and oil pump shaft adapter asshown in Figure 5.7A. Inspect the gears in the oilpump for corrosion or pitting and replace ifnecessary. Check the oil pump shaft bushing in thebearing carrier. If the bushing is corroded, pitted orworn, the oil pump shaft bushing should be replaced.

Before reassembling the oil pump mechanism,replace the 0-rings in the oil pump cover and on theoil pump adapter shaft (see Figure 5.7A). Rotate thedrive pin in the crankshaft to a vertical position foreasiest reassembly. Insert the shaft adapter so itengages the drive pin. Next, insert the spring, spring

guide and oil pump assembly. The tang on the oilpump must align with the slot in the shaft adapter.Install the pump cover so the pin on the case is in theopening on the oil pump assembly as shown inFigure 5.7A. When you are sure the pin is properlyaligned, install the cover bolts finger tight. Rotatethe crankshaft by hand to ensure smooth operation.Then rotate it in opposite directions, listening for aclick, which indicates proper alignment of the oilpump’s pins and slots. Finally, tighten the bolts in analternating sequence. See Section 3.3 for directionson oil pressure adjustment.

BEARING CARRIER REPLACEMENTFIGURE 5.6.3A


FIGURE 5.7A


5.8 SERVICING THE FOUR-WAY VALVE

Unlike older units, new Corken compressorsmounted in the –107 arrangement are beingsupplied with a non-lube four-way valve. Nomaintenance is normally required on this valve. Ifyou have reason to disassemble the valve, pleasefollow the instructions below.

CAUTION: Always Relieve Pressure In The UnitBefore Attempting Any Repairs.

BEFORE DISASSEMBLY:

1. Record the position marks on the end of therotor shaft.

2. Record the positions of the handle stops on the cap.

NOTE: Asmall amount of silicone grease applied to eachpart before assembly facilitates assembly if allowed.

DISASSEMBLY: Refer to the drawing for itemdescription.

1. Remove the hex nut, indicator plate and handlefrom the rotor shaft.

2. Remove the four hex head bolts and the cap from thebody. Cap should be rotated until free, do not pry.

Inspect cap for wear and damage.

3. Remove the body O-ring, stem O-ring,, cap O-ring, and top rotor washer and discard.

4. Remove the rotor and four seals as a unit from thebody. IMPORTANT: Because of the close

tolerance, care must be taken to remove the rotoron its axis to prevent damage to the rotor andbody. Rotating the handle with a lifting action willhelp remove the rotor.

5. Discard the four seals. Inspect the rotor for wearand damage.

6. Remove the bottom rotor washer and discard.Inspect the body for wear and damage.

REASSEMBLY: Refer to drawing. Have Repair Kitlaid out.

1. Place the new bottom rotor washer into the body.

2. Assemble the four seals and 0-rings onto theappropriate surfaces of the rotor.

3. Assemble the rotor and seal assembly into the body.


Following a few simple procedures will greatlyminimize the risk of the unit becoming corroded anddamaged. Corken recommends the followingprecautions to protect the compressor during storage:

1. Drain the crankcase oil and refill with rustinhibiting oil.

2. Operate for a few minutes while fogging oil intothe compressor suction.

3. Relieve V-belt tension.

4. Plug all openings to prevent entry of insects andmoisture. (The cylinders may also be protectedby the use of a vapor phase inhibitor, silica gel,or dry nitrogen gas. If the silica gel is used, hanga tag on the unit indicating that it must beremoved before a start-up.)

5. Store in a dry area, off the ground if possible.

6. Rotate the flywheel every two weeks if possible.

IMPORTANT: Because of the close tolerance,care must be taken to press the rotor on its axisto prevent damage to the rotor and body. A ringcompressor is helpful. Be sure that the rotor isbottomed in the body.

4. Assemble the new top rotor washer and cap O-ring, onto the shoulder of the rotor.

5. Assemble the new stem o-ring and the body o-ringinto their grooves in the rotor and body.

6. Place the cap over the rotor shaft.

7. Assemble the four hex head bolts through the capand into the body. Be sure that the body o-ring is inthe proper position and tighten the hex head bolts.

8. Reassemble the handle, indicator plate and hexnut. Be sure that the handle is assembled so thatthe stop on the handle mates with the stops onthe cap.

CHAPTER 6EXTENDED STORAGE PROCEDURES

ROTATE THE ROTOR SO THAT THEPOSITION MARKS ON THE END OFTHE ROTOR SHAFT ARE THE SAME ASRECORDED BEFORE DISASSEMBLY.

ROTATE THE ROTOR SO THAT THEPOSITION OF THE HANDLE STOPS ONTHE CAP ARE THE SAME ASRECORDED BEFORE DISASSEMBLY.


MODELS INVOLVED DESCRIPTION CODE FEATURE

HEADALL ANSI/DIN FLANGE INLET AND OUTLET F CONNECTION

STYLE

SINGLE-STAGE, DUCTILE IRON NOTE: MODELS ARE AVAILABLE 91, 291NOTE: MODELS ARE AVAILABLE WITH DIN IRON HEAD/CYLINDER 491/492 BASICMODEL NO. WILL BE DESIGNATED BY A "2" THE LAST DIGIT OF 491-3 MODELTHE MODEL NO. 691/692

ALL INLET PRESSURE ABOVE ATMOSPHERIC A PACKINGADJUSTMENT

91 ONLY SPLASH LUBRICATED CRANKCASE J91-491 EXTENDED CRANKSHAFT EALL EXCEPT 91 STANDARD PRESSURE LUBRICATED CRANKCASE MALL EXCEPT 91 STANDARD CRANKCASE WITH CRANKCASE HEATER MH CRANKCASEALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR L STYLE

LUBRICATORALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR LH

LUBRICATOR AND CRANKCASE HEATER

ALL LIQUID RELIEF SUCTION VALVES 3ALL STANDARD SUCTION AND DISCHARGE VALVES 4ALL SUCTION VALVE UNLOADERS 9 VALVESALL EXCEPT 391-491 SPEC 4 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES 4PALL EXCEPT 391-491 SPEC 9 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES 9P

91-491 SERIES PTFE PISTON RING AND PACKING MATERIAL F PISTON RING691 PTFE PISTON RING AND ALLOY 50 PACKING MATERIAL AND PACKINGALL SAME AS F WITH THE ADDITION OF K-RING SPACERS FK MATERIAL

ALL ALUMINUM GASKET MATERIAL B GASKETALL COPPER GASKET MATERIAL C MATERIALALL IRON-LEAD GASKET MATERIAL D

ALL BUNA-N A O-RINGALL NEOPRENE* B MATERIALALL VITON* D

ALL SINGLE STAGE NOT APPLICABLE - SINGLE STAGE COMPRESSOR N INTERCOOLERCOMPRESSORS (NO INTERCOOLER)

191-491 SERIES ONLY 14" FLYWHEEL USED IN CONJUNCTION WITH EXTENDED ECRANKSHAFT

91-491 SERIES ONLY HEAVY DUTY FLYWHEEL H FLYWHEELALL NO FLYWHEEL SUPPLIED NALL STANDARD FLYWHEEL S

ALL NO COATING N PROTECTIVECOATING

ALL NITROTEC PISTON ROD COATING (STANDARD) N PISTON RODCOATING

491A

M3

FB

AN

SN

N

EXAMPLEM

ODEL NUMBER

MODEL NUMBER AND MOUNTING IDENTIFICATION CODE

*VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT.

APPENDIX A


STANDARD OPTIONAL

PART SIZE MATERIAL SIZE MATERIAL

HEAD, CYLINDER 91, 291, 491, 691 DUCTILE IRON ASTM A536 NONE

CROSSHEAD GUIDECRANKCASE, FLYWHEEL ALL GRAY IRON ASTM A48, CLASS 30 NONEBEARING CARRIER

FLANGE 691 DUCTILE IRON ASTM A536 690,691 STEEL WELDING

VALVE SEAT AND BUMPER 91,291 17-4 PH STAINLESS STEEL NONE491 DUCTILE IRON ASTM A536691 GRAY IRON ASTM A48, CLASS 30

VALVE PLATE 91,291 410 STAINLESS STEEL NONE491 17-7 PH STAINLESS STEEL691 STEEL, ROCKWELL 50C

VALVE SPRING 91,291,691 17-7 PH STAINLESS STEEL NONE491 INCONEL

VALVE GASKETS ALL SOFT ALUMINUM ALL IRON-LEAD

PISTON ALL GRAY IRON ASTM A48, CLASS 30 NONE

C1050 STEEL,PISTON ROD ALL HARD CHROMIUM PLATED NONE

ROCKWELL 60C

CROSSHEAD ALL GRAY IRON ASTM A48, CLASS 30 NONE

PISTON RINGS ALL PTFE, GLASS- AND MOLY-FILLED NONE

PISTON RING EXPANDERS ALL 302 STAINLESS STEEL NONE

HEAD GASKET 91, 291, 491, 691 O-RING (BUNA-N) 91,290,291, 491, 691 PTFE, VITON, NEOPRENE*

ADAPTER PLATE,PACKING CARTRIDGE, ALL DUCTILE IRON ASTM A536 NONECONNECTING ROD

PACKING RINGS ALL PTFE, GLASS- AND MOLY-FILLED NONE

CRANKSHAFT ALL DUCTILE IRON ASTM A536 NONE

CONNECTING ROD ALL BIMETAL D-2 BABBIT NONEBEARING

WRIST PIN ALL C1018 STEEL, ROCKWELL 62C NONE

WRIST-PIN BUSHING ALL BRONZE SAE 660 NONE

MAIN BEARING ALL TAPERED ROLLER NONE

INSPECTION PLATE ALL ALUMINUM NONE

O-RINGS ALL BUNA-N ALL PTFE, VITON, NEOPRENE*

RETAINER RINGS ALL STEEL NONE

MISCELLANEOUS GASKETS ALL COROPRENE NONE

*VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT.

MATERIAL SPECIFICATIONS

APPENDIX B


SINGLE STAGE

Specifications 91 290 291 490 491 690 691

Cylinder Bore, Inches (cm) 3 3 3 4 4 4.5 4.5First Stage (7.62) (7.62) (7.62) (10.16) (10.16) (11.43) (11.43)

Stroke, 2.5 2.5 2.5 3 3 4 4Inches (cm) (6.35) (6.35) (6.35) (7.62) (7.62) (10.16) (10.16)

Piston DisplacementCFM (Lit/Min)Min. at 300 RPM 3 (85) 6 (170) 6 (170) 13 (368) 13 (368) 22 (623) 22 (623)Max. at 825 RPM 8 (226) 16 (453) 16 (453) 36 (1019) 36 (1019) 60 (1699) 60 (1699)

*Max. Pressure 350 280 350 280 350 280 350psia (bars) (24.14) (19.31) (24.14) (19.31) (24.14) (19.31) (24.14)

Max. Motor Size HP 7.5 15 15 15 15 35 35

Max. Outlet 350 350 350 350 350 350 350Temperature °F (°C) (177) (177) (177) (177) (177) (177) (177)

* These numbers specify pressure-containing abilities of the compressor cylinder and head. For many applications,factors other than the pressure rating will limit the maximum allowable discharge pressure to lower values. Thesefactors include horsepower, temperature and rod load.

MECHANICAL SPECIFICATIONS

APPENDIX C


SIZE CONN. BEARING BEARING CRANK- X-HEAD CYL. VALVE VALVE PISTON PISTON VALVE VALVEROD CARRIER COVER CASE GUIDE TO COVER HOLD- LOCK SCREW CAP CAPBOLT FT-LB FT-LB INSPEC FT-LB HEAD PLATE DOWN NUT TORQUE TORQUE TORQUEFT-LB PLATE (1,2) BOLT SCREW TORQUE IN-LB (W/ GASKETS) (W/ O-RINGS)

FT-LB FT-LB FT-LB 2 FT-LB FT-LB FT-LBFT-LB

91 28 38 38 15 30 20 -- 40 45 50 40 25

291 28 30 30 13 25 20 -- 40 45 50 40 25

491 30 26 35 8 33 33 35 40 45 100 40 25

691 40 40 40 9 40 30 37 40 60 100 40 25

(1) Preliminary tightening – snug all headbolts in the sequence shown. Final torqueing – torque all headbolts in the sequence shown to the listed value.(2) Retorque to the listed value after 2 – 5 hours running time.

BOLT TORQUE VALUES

APPENDIX D


91 291 491 691(M Crankcase)

**Clearance: "X" Piston 0.020 0.020 0.000/0.020 0.000/0.015Fig. 5.4A & 5.4B 0.044 0.044 0.024/0.044 0.012/0.027

Clearance: Conrod bearing to 0.0005 0.0005 0.0005 0.0019crankshaft journal 0.0025 0.0025 0.0025 0.0035

Clearance: Wrist pin to wrist pin 0.0009 0.0009 0.0009 0.0020bushing* (max)

Cylinder Bore Diameter (max) 3.009 3.009 4.011 4.515

Cylinder Finish (RMS) 16-32 16-32 16-32 16-32

Piston ring radial thickness (min) 0.082 0.082 0.082 0.082

Clearance: Oil pump adapter shaft 0.0050 0.0050 0.0050 0.0050to bushing* (max)

Crankshaft end play (cold) 0.000 0.000 0.000 0.002

0.002 0.002 0.002 0.003

Flywheel runout at O.D. (max) 0.020 0.020 0.020 0.020

Clearance: Crosshead to crosshead 0.011 0.011 0.012 0.013guide bore (max)

Crosshead guide bore finish 32 RMS (limited number of smallpits and scratches are acceptable)

* Dimensions for honing are included with new bushings (which must be installed, then honed).** Clearance should be set with machine cold .

CLEARANCES AND DIMENSIONS

APPENDIX E

ALL DIMENSIONS ARE IN INCHES.


PROPANE COMPRESSOR SELECTION TABLE

SERVICE GPM (1) CFM MODEL RPM 1750 RPM 1460 RPM 100˚F 80˚F 100˚F 80˚F VAPOR LIQUID

23 4 91 400 A 3.0 A 3.6 5 3 3 3 t 1qSMALL 29 5 91 505 A 3.8 B 4.6 5 5 5 5 t 1qBULK 34 6 91 590 B 4.6 B 5.6 5 5 5 5 1 1q

PLANTS 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1q39 7 291 345 A 3.0 A 3.6 3 3 3 3 1 1q

45 8 91 795 B 6.2 B 7.4 7h 7h 7h 7h 1 1h44 8 291 390 A 3.4 B 4.0 5 3 3 3 1 1h50 9 291 435 A 3.8 B 4.6 5 3 3 3 1 1h56 10 291 490 B 4.4 B 5.2 5 5 5 5 1 2

UNLOADING 61 11 291 535 B 4.8 B 5.8 5 5 5 5 1 2SINGLE TANK 66 12 291 580 B 5.2 B 6.2 7h 5 5 5 1 2

CARS OR 71 13 291 625 B 5.6 B 6.6 7h 5 7h 5 1q 2TRANSPORT 79 14 291 695 B 6.2 B 7.4 7h 7h 7h 7h 1q 2

84 15 291 735 B 6.6 B 8.0 10 7h 10 7h 1q 2h84 15 491 345 A 3.0 A 3.6 7h 7h 5 5 1q 2h89 16 491 780 B 7.0 B 8.6 10 10 10 10 1q 2h89 16 491 370 A 3.2 A 3.8 7h 7h 7h 5 1q 2h

95 17 491 390 A 3.4 B 4.0 7h 7h 7h 7h 1q 3101 18 491 415 A 3.6 B 4.4 10 7h 7h 7h 1q 3106 19 491 435 A 3.8 B 4.6 10 7h 7h 7h 1q 3108 20 491 445 B 4.0 B 4.8 10 7h 7h 7h 1q 3114 21 491 470 B 4.2 B 5.0 10 7h 7h 7h 1q 3

UNLOADING 119 22 491 490 B 4.4 B 5.2 10 10 7h 7h 1q 3TWO OR MORE 125 23 491 515 B 4.6 B 5.6 10 10 10 7h 1q 3TANK CARS AT 130 24 491 535 B 4.8 B 5.8 15 10 10 10 1q 3

ONE TIME, 136 25 491 560 B 5.0 B 6.0 15 10 10 10 1q 3OR LARGE 141 26 491 580 B 5.2 B 6.2 15 10 10 10 1q 3

TRANSPORT 147 27 491 605 B 5.4 B 6.4 15 10 15 10 1q 3WITH EXCESS 152 28 491 625 B 5.6 B 6.6 15 15 15 15 1h 3FLOW VALVES 158 29 491 650 B 5.8 B 7.0 15 15 15 15 1h 3OF ADEQUATE 163 30 491 670 B 6.0 15 15 15 15 1h 3

CAPACITY 163 30 691 400 B 4.4 B 5.2 15 15 10 10 1h 3168 31 491 695 B 6.2 B 7.4 15 15 15 15 1h 3171 31 691 420 B 4.6 B 5.6 15 15 10 10 1h 3179 32 491 740 B 6.6 B 8.0 15 15 15 15 1h 3178 32 691 440 B 4.8 B 5.8 15 15 10 10 1h 3186 34 691 455 B 5.0 B 6.0 15 15 15 10 1h 3193 35 691 475 B 5.2 B 6.2 15 15 15 10 1h 3200 36 691 495 B 5.4 B 6.4 15 15 15 15 1h 3

208 38 691 510 B 5.6 B 6.8 20 15 15 15 1h 4215 39 691 530 B 5.8 B 7.0 20 15 15 15 1h 4

UNLOADING 223 41 691 550 B 6.0 A 7.0 20 15 15 15 1h 4LARGE TANK 230 42 691 565 B 6.2 B 7.4 20 15 15 15 2 4

CARS, MUTIPLE 237 43 691 585 B 6.4 A 7.4 20 15 15 15 2 4VESSELS, 245 45 691 605 B 6.6 B 8.0 20 15 15 15 2 4

BARGES OR 252 46 691 620 B 6.8 20 20 15 15 2 4TERMINALS 260 47 691 640 B 7.0 A 8.2 20 20 20 15 2 4

275 48 691 675 B 7.4 B 8.6 25 20 20 20 2 4297 54 691 730 B 8.0 B 9.4 25 20 20 20 2 4319 58 691 785 B 8.6 25 20 25 20 2 4334 60 691 820 TB9.0 A 10.6 30 25 25 20 2 4

Consult factory for compressors for higher flows.

NOTES: (1) The capacities shown are based on 70˚F, but will vary depending upon piping, fittings used, product being transferred and temperatures. The factory can supply a detailed computer analysis if required.

(2) Driver sheaves; 91-2 belts; 290, 291, 490, 491-3 belts; 690, 691-4 belts.(3) The piping sizes shown are considered minimum. If the length exceeds 100 ft., use the next larger size.

DRIVER HORSEPOWERLIQUID LIQUID

TRANSFER TRANSFERAND WITHOUT

RESIDUAL RESIDUALDRIVER SEAVE VAPOR VAPOR PIPING SIZE

CAPACITY DISPLACEMENT COMPRESSOR SIZE P.D.* (2) RECOVERY RECOVERY (3)

APPENDIX F


N-BUTANE COMPRESSOR SELECTION TABLE



PLANTS 24 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1h23 7 291 345 A 3.0 A 3.6 2 2 2 2 1 1h

27 8 91 795 B 6.2 B 7.4 5 5 5 5 1 1h26 8 291 390 A 3.4 B 4.0 2 2 2 2 1 1h30 9 291 435 A 3.8 B 4.6 3 3 3 3 1 1h33 10 291 490 B 4.4 B 5.2 3 3 3 3 1 2

UNLOADING 36 11 291 535 B 4.8 B 5.8 3 3 3 3 1 2SINGLE TANK 39 12 291 580 B 5.2 B 6.2 5 3 5 3 1 2

CARS OR 42 13 291 625 B 5.6 B 6.6 5 5 5 5 1q 2TRANSPORT 47 14 291 695 B 6.2 B 7.4 5 5 5 5 1q 2

50 15 291 735 B 6.6 B 8.0 5 5 5 5 1q 2h50 15 491 345 A 3.0 A 3.6 5 5 5 5 1q 2h53 16 291 780 B 7.0 B 8.6 7h 5 7h 5 1q 2h53 16 491 370 A 3.2 A 3.8 5 5 5 5 1q 2h

56 17 491 390 A 3.4 B 4.0 5 5 5 5 1q 360 18 491 415 A 3.6 B 4.4 5 5 5 5 1q 363 19 491 435 A 3.8 B 4.6 5 5 5 5 1q 365 20 491 445 B 4.0 B 4.8 5 5 5 5 1q 368 21 491 470 B 4.2 B 5.0 5 5 5 5 1q 371 22 491 490 B 4.4 B 5.2 7h 5 7h 5 1q 375 23 491 515 B 4.6 B 5.6 7h 5 7h 5 1q 3

UNLOADING 77 24 491 535 B 4.8 B 5.8 7h 7h 7h 7h 1q 3TWO OR 81 25 491 560 B 5.0 B 6.0 7h 7h 7h 7h 1q 3

MORE TANK 84 26 491 580 B 5.2 B 6.2 7h 7h 7h 7h 1q 3CARS AT 87 27 491 605 B 5.4 B 6.4 7h 7h 7h 7h 1q 3

ONE TIME, 91 28 491 625 B 5.6 B 6.6 7h 7h 7h 7h 1h 3OR LARGE 94 29 491 650 B 5.8 B 7.0 10 7h 10 7h 1h 3

TRANSPORT 97 30 491 670 B 6.0 10 7h 10 7h 1h 3WITH EXCESS 94 30 691 400 B 4.4 B 5.2 7h 7h 7h 7h 1h 3

FLOW 100 31 491 695 B 6.2 B 7.4 10 7h 10 7h 1h 3VALVES OF 98 31 691 420 B 4.6 B 5.6 10 7h 10 7h 1h 3ADEQUATE 107 32 491 740 B 6.6 B 8.0 10 10 10 10 1h 3CAPACITY 103 32 691 440 B 4.8 B 5.8 10 7h 10 7h 1h 3

110 33 491 760 B 6.8 B 8.0 10 10 10 10 1h 3113 34 491 780 B 7.0 B 8.6 10 10 10 10 1h 3107 34 691 455 B 5.0 B 6.0 10 10 10 10 1h 3111 35 691 475 B 5.2 B 6.2 10 10 10 10 1h 3119 36 491 825 B 7.4 B 8.6 15 10 15 10 1h 3116 36 691 495 B 5.4 B 6.4 10 10 10 10 1h 3

120 38 691 510 B 5.6 B 6.8 10 10 10 10 1h 4124 39 691 530 B 5.8 B 7.0 10 10 10 10 1h 4

UNLOADING 129 41 691 550 B 6.0 A 7.0 10 10 10 10 1h 4LARGE 133 42 691 565 B 6.2 B 7.4 10 10 10 10 2 4

TANK CARS, 137 43 691 585 B 6.4 A 7.4 10 10 10 10 2 4MULTIPLE 142 45 691 605 B 6.6 B 8.0 15 10 15 10 2 4VESSELS, 145 46 691 620 B 6.8 15 10 15 10 2 4

BARGES OR 150 47 691 640 B 7.0 A 8.2 15 10 15 10 2 4TERMINALS 158 48 691 675 B 7.4 B 8.6 15 15 15 15 2 4

184 54 691 730 B 8.0 B 9.4 15 15 15 15 2 4184 58 691 785 B 8.6 15 15 15 15 2 4193 60 691 820 TB9.0 A 10.6 15 15 15 15 2 4








APPENDIX F2


AMMONIA COMPRESSOR SELECTION TABLE



PLANTS 40 7 91 695 B 5.4 B 6.6 5 5 5 5 1 1h43 7 291 345 A 3.0 A 3.6 3 3 3 3 1 1h

46 8 91 795 B 6.2 B 7.4 7h 5 5 5 1 1h45 8 291 390 A 3.4 B 4.0 5 3 3 3 1 1h50 9 291 435 A 3.8 B 4.6 5 3 3 3 1 1h56 10 291 490 B 4.4 B 5.2 5 5 5 3 1 2

UNLOADING 62 11 291 535 B 4.8 B 5.8 7h 5 5 5 1 2SINGLE TANK 67 12 291 580 B 5.2 B 6.2 7h 5 5 5 1 2

CARS OR 72 13 29/1 625 B 5.6 B 6.6 7h 5 5 5 1q 2TRANSPORT 80 14 291 695 B 6.2 B 7.4 7h 7h 7h 5 1q 2

85 15 291 735 B 6.6 B 8.0 10 7h 7h 7h 1q 2h85 15 491 345 A 3.0 A 3.6 7h 7h 5 5 1q 2h90 16 491 780 B 7.0 B 8.6 10 7h 7h 7h 1q 2h90 16 491 370 A 3.2 A 3.8 10 7h 5 5 1q 2h

96 17 491 390 A 3.4 B 4.0 10 7h 5 5 1q 3102 18 491 415 A 3.6 B 4.4 10 7h 7h 7h 1q 3107 19 491 435 A 3.8 B 4.6 10 7h 7h 7h 1q 3110 20 491 445 B 4.0 B 4.8 10 7h 7h 7h 1q 3115 21 491 470 B 4.2 B 5.0 10 7h 7h 7h 1q 3

UNLOADING 120 22 491 490 B 4.4 B 5.2 15 10 7h 7h 1q 3TWO OR 126 23 491 515 B 4.6 B 5.6 15 10 7h 7h 1q 3

MORE TANK 131 24 491 535 B 4.8 B 5.8 15 10 10 7h 1q 3CARS AT 138 25 491 560 B 5.0 B 6.0 15 10 10 7h 1q 3

ONE TIME, 142 26 491 580 B 5.2 B 6.2 15 10 10 7h 1q 3OR LARGE 148 27 491 605 B 5.4 B 6.4 15 10 10 10 1q 3

TRANSPORT 153 28 491 625 B 5.6 B 6.6 15 10 10 10 1h 3WITH EXCESS 160 29 491 650 B 5.8 B 7.0 15 15 10 10 1h 3

FLOW 165 30 491 670 B 6.0 15 15 15 10 1h 3VALVES OF 165 30 691 400 B 4.4 B 5.2 15 15 10 10 1h 3ADEQUATE 170 31 491 695 B 6.2 B 7.4 15 15 15 10 1h 3CAPACITY 173 31 691 420 B 4.6 B 5.6 15 15 10 10 1h 3

181 32 491 740 B 6.6 B 8.0 15 15 15 15 1h 3180 32 691 440 B 4.8 B 5.8 15 15 10 10 1h 3188 34 691 455 B 5.0 B 6.0 20 15 10 10 1h 3195 35 691 475 B 5.2 B 6.2 20 15 10 10 1h 3203 36 691 495 B 5.4 B 6.4 20 15 15 10 1h 3

211 38 691 510 B 5.6 B 6.8 20 15 15 10 1h 4218 39 691 530 B 5.8 B 7.0 20 15 15 15 1h 4

UNLOADING 226 41 691 550 B 6.0 A 7.0 20 15 15 15 1h 4LARGE 233 42 691 565 B 6.2 B 7.4 20 15 15 15 2 4

TANK CARS, 240 43 691 585 B 6.4 A 7.4 20 20 15 15 2 4MULTIPLE 248 45 691 605 B 6.6 B 8.0 20 20 15 15 2 4VESSELS, 255 46 691 620 B 6.8 25 20 15 15 2 4

BARGES OR 264 47 691 640 B 7.0 A 8.2 25 20 15 15 2 4TERMINALS 278 48 691 675 B 7.4 B 8.6 25 20 15 15 2 4

301 54 691 730 B 8.0 B 9.4 25 20 20 15 2 4323 58 691 785 B 8.6 30 25 20 20 2 4334 60 691 820 TB9.0 A 10.6 30 25 25 20 2 4








APPENDIX F3


COMPRESSOR TROUBLESHOOTING

In most cases, problems with your Corken GasCompressor can be solved quite simply. This chartlists some of the more frequent problems that occurwith reciprocating compressors along with a list of

possible causes. If you are having a problem whichis not listed, or if you cannot find the source of theproblem, consult the factory.

PROBLEM POSSIBLE CAUSE

Low capacity 1, 2, 3, 4, 16Overheating 1, 2, 3, 5, 6, 11, 15Knocks, rattles and noise 1, 7, 9, 10, 11, 14Oil in cylinder 8, 14Abnormal piston-ring wear 1, 3, 5, 6, 11, 14, 15Product leaking through crankcase breather 8, 14Product leakage 4, 8, 14, 16Oil leakage around compressor base 17, 18No oil pressure 19, 20Excessive vibration 1, 7, 9, 10, 11, 12, 13, 28Motor overheating or starter tripping out 21, 22, 23, 24, 25, 26, 27, 28

REF. POSSIBLE CAUSES WHAT TO DO

1. Valves broken, stuck or leaking Inspect and clean or repair2. Piston ring worn Inspect and replace as necessary3. Inlet strainer clogged Clean or replace screen as necessary4. Leaks in piping Inspect and repair5. Inlet or ambient temperature too high Consult factory6. Compression ratio too high Check application and consult factory7. Loose flywheel or belt Tighten8. Worn piston-rod packing Replace9. Worn wrist pin or wrist-pin bushing Replace

10. Worn connecting-rod bearing Replace11. Unbalanced load Inspect valve or consult factory12. Inadequate compressor base Strengthen, replace or grout13. Improper foundation or mounting Tighten mounting or rebuild foundation14. Loose valve, piston or packing Tighten or replace as necessary15. Dirty cooling fins Clean weekly16. 4-way control valve not lubricated Inspect and lubricate17. Leaking gas blowing oil from crankcase Tighten packing18. Bad oil seal Replace19. No oil in crankcase Add oil20. Oil-pump malfunction See oil-pressure adjustment21. Low voltage Check line voltage with motor nameplate. Consult power company22. Motor wired wrong Check wiring diagram23. Wire size too small for length or run Replace with correct size24. Wrong power characteristics Voltage, phase and frequency must coincide with motor nameplate. Consult with power company.25. Wrong size of heaters in starter Check and replace according to manufacturer’s instructions26. Compressor overloading Reduce speed27. Motor shorted out See driver installation28. Bad motor bearing Lubricate according to manufacturer’s instructions

APPENDIX G


Compressor Model # Serial #

RPM Package #

Motor BHP , Frame , RPM , F.L. Amps , Manuf.

Installation Date Start-up Date

Customer

Location

Field Contact Telephone #

Make and Grade of Oil

Pressure-Switch Settings:

Suction Pressure Discharge Pressure

Date Time Outside Temperature Hour Meter

Readings: Suction Pressure Suction Temperature

Discharge Pressure Discharge Temperature

Check List: Oil Level Strainers

Change Oil Valve Positions

Flywheel Bolts Belt Tension

Mounting Bolts Gauges (Zero Position)

Motor Amperage Drain Liquid Trap

Additional Notes:

Checked By:

CORKEN COMPRESSOR LOG SHEET (ELECTRIC-DRIVEN UNITS)

APPENDIX H

P.O. Box 12338, Oklahoma City, OK 731573805 N.W. 36th St., Oklahoma City, OK 73112Phone (405) 946-5576 • Fax (405) 948-7343

E-mail [email protected] address www.corken.com

Printed in U.S.A.September 1999

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